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Picked up a 2001 Passat 1.8L that "needed a new motor"

12K views 39 replies 16 participants last post by  DualVdub  
#1 · (Edited)
So last weekend I pick up a 2001 GLS 1.8L with about 129,500 K miles, the ad said the motor needed to be replaced because metal was in the oil. After some research I found out these cars have a oil sludge problem, so worst case the engine would have to be replaced. ( I can also pick one up from Pick-n-Pull for petty cheap)

When I picked the car the owner told that a local repair shop told her the motor had metal in the oil and that she needed a new motor. So after letting the car sit for over a year she sold it to me for under a grand and has given me the number to local shop. I called the shop the next day and asked shop owner what problems did the car have, he told me the car had oil low pressure and metal in the oil.

Today was the 1st day I had time to work on the car, the 1st thing I did was remove the valve cover. To my surprise it was petty clean, still had a light brown color tint to everything but no oil sludge, no evidence of metal particles. Next thing I did was drain the oil, once again petty clean however when the oil stop flowing out and started to drip out I could see little black specks in the oil. I removed the oil level sensor in the forward bottom of the oil pan and used an inspection mirror to look around, once again as far as I could tell everything was petty clean and I found no evidence of metal particles. I did find coked oil along the sides of the oil pan walls. Now I can't figure out where the local car shop came up with metal in the oil, as I can tell the oil panhas never been removed ever. :hmmm: I than removed a camshaft cap looking for metal scoring, but I found a speck of coked oil.

So I got in contact with the last owner and I asked her what happen to the car that made her bring it to a shop. She told me the "STOP" engine light came on and the car wouldn't go over 15 MPH, it just struggled to run and it shook. Now when I removed the valve cover I did notice the black rubber tube with 3 ports had a HUGH hole on the bottom side, it was so big my finger could fit inside, which = Vacuum/Boost leak. :thumbdown

Here is a pic of the hose I'm talking about with the hole (Red being the hole):


I checked for CEL codes with my scanner and I got P0011 Intake Camshaft Position Timing Over-Advanced. Looking at the Freeze Frame Data when the code pop, this is what I got.

Calc Engine Load(%)= 90.98%
ECT (coolant) = 197 degrees
Eng RPM = 5440
Veh Speed = 24 MPH
Short Term Fuel Trim = 3.13%
Long Term Fuel Trim = 0%

So from what I'm finding I thing the car has a major vacuum leak problem, and maybe a coil pack problem. I also need to see what this P0011 code is about, but I don't have a Passat FSM. Also is there a way to see if the coil packs had been replaced in the past (i.e. revised part number for the coil packs):confused:
 
#2 ·
I wouldn't worry about the coil packs just yet. You should check the timing and see if the timing belt has slipped for some reason and bent the valves.

16395/P0011/000017 - Bank 1: Camshaft A (Intake): Retard Setpoint not Reached (Over-Advanced)


Possible Symptoms
Power Loss

Possible Causes
Camshaft Adjustment Valve 1 (N205) faulty
Fuel Pump Relay (J17) faulty
Mechanical Timing not correct, including Chain and/or Belt timing.

Possible Solutions
Check Camshaft Adjustment Valve 1 (N205)
Check Fuel Pump Relay (J17)
Check Mechanical Timing
 
#3 ·
what's the engine code?

I agree with 2002GLXV6, forget the coilpacks for now. your first priority is making sure mechanical timing, i.e., the timing belt and camshafts, is correct.

Have you looked at the chain tensioner? you may need to remove it (or slightly lift it off and use a mirror) to inspect the oil screen underneath. if it's clogged with particles it won't give you proper timing on the intake side (which is where the cam position sensor is). if you have VVT, there is a solenoid on the CCT also, so check that too. The CCT pads are also an item and can wear down and cause parts of it to end up in the oil pan.

P.S. the CCT requires a special tool to compress it. when you get this tool, turn the screw very very slowly and stop before the tool bucks. to remove the CCT you'll need to remove the intake cam so you can get enough slack on the chain.
 
#22 ·
Your first priority is making sure mechanical timing, i.e., the timing belt and camshafts, is correct.

Have you looked at the chain tensioner? you may need to remove it (or slightly lift it off and use a mirror) to inspect the oil screen underneath. if it's clogged with particles it won't give you proper timing on the intake side (which is where the cam position sensor is). if you have VVT, there is a solenoid on the CCT also, so check that too. The CCT pads are also an item and can wear down and cause parts of it to end up in the oil pan.
So I Checked mechanical timing today and everything lines up :D So I'm very happy about that. I also pulled the intake cam and chain tensioner, there were a few specks of coked oil on the screen and under the camshaft caps. I forget to removed the CCT solenoid to check but I will.

So far everything I looked at would "suggest" the car loss oil pressure to coked oil build up or block oil pump screen, but I not found any evidence of metal in the oil. I also check for turbo shaft play and I petty much don't have any play. The turbine also spins freely.

My plan is to the replace the valve cover gasket, and the 3 port breather hose connector, install a oil pressure gauge, fill the car with oil and go for a drive to see if I lose power.
 
#5 ·
What special tool do you need to remove the fans? To remove the belt-driven fan, use a drift or a small hex wrench you won't miss much, sit it the two slots on the bracket and slide it forward until it goes through the hole in the fan; this fixes the fan in place, no special tool necessary.
 
#8 ·
http://www.passatworld.com/forums/6...-advice-sought-non-running-project-car-potential-timing-issue-head-rebuild.html

You are probably in the same boat as me, likely a timing issue and probably has bent valves requiring a head rebuild or replacement. If you are very lucky you may want to start by verifying that the timing belt is still in place (check to make sure the marks line up), check that the PCV system is intact, then check the compression, and if that's ok then try starting it up while connected to an oil pressure guage and verify that the oil pump is making spec pressures.

You've only looked at one cam cap? I would probably pull the cams out entirely and replace the CCT and verify that there is no abnormal wear on any of them and that the oil feed holes to each cam journal are not plugged with those black cruddy coke bits. After that (if everything looks ok) I would pull the oil pan and clean it and replace the pump and pickup tube.
 
#9 ·
First the hose, is it this hose?
Volkswagen Passat B5 FWD 1.8T > Engine > Emissions > ES#6992 Breather Hose Connector - 06B103221P

I would also check the hose coming out of the oil filter adapter, or this hose
Volkswagen Passat B5 FWD 1.8T > Search > 06A103213 > ES#7934 Breather Hose Elbow - 06A103213F

These are part of the PCV system. They seem to be a regular maintenance item. I just replaced them on my model.

VW had a major recall on these engines due to the oil pickup tube clogging up from sludge in the oil and causing a loss of oil pressure. The TSB called for the shop to remove the valve cover, remove each cam cap and checking for abnormal wear. If any signs of unusual wear was found in the cam area they would replace the engine at no cost. If nothing unusual was found they would replace the oil pickup, run some cheap oil & flush thru it for 30 minutes, drain, remove pan and check pickup for debris again, and then reinstall pickup and fill with proper oil.
 
#13 ·
As far as the TSB, I thought for the to be free the car still had to be under warranty.
It actually wasn't part of the warranty program, it was two successive settlements to class action suits about the problem. Unfortunately, a 2001 with 129,000 miles is past the limits of both of them. There are details in one of the sticky threads in this forum.
 
#27 ·
#28 · (Edited)
So the diesel treatment and engine flush was a waste of time. After I fill the car with fresh oil and Mann filter I got the "STOP" light as soon as I pulled out the driveway.

It's looking like I have do what I really don't want and that's drop the oil pan, and start cleaning.:wrench:

EDIT; just ordered a Oil Pump, Oil Pick-up Tube and o-ring from ECS. I guess tomorrow I'll start pulling the oil pan.
 
#29 ·
What do your oil pressure numbers look like? Please don't tell me that you haven't even bothered to install a pressure gauge yet!

So, lemme get this straight: you got it up and running and it sounds ok at idle, but when you left the driveway the oil pressure warning came on. Did it go away once you got up to speed? Did you just drive back into the driveway and shut it down? You really need those oil pressure numbers from an external mechanical pressure gauge!
 
#32 · (Edited)
So today I dropped the oil pan, its was not that bad of a job.

Not to any surprise there was tons of carbon build up on the oil pan walls, the engine block walls, the oil pump. The oil pump pick up screen was clogged with OEM engine sealant, coked oil, not a single part of the screen was clear I cannot see through the mesh filter at all. I petty much spend most of my day cleaning, the oil pan is so clean now I can lick it.

EDIT: I also pulled the #2 main cap to inspected for damage to crank and bearing. I found nothing out of the norm. :lol: